~ EI&ltV

Indax
Paga 1 (1)
Trouble Tracing 603

AliancaJ
CCN 196
Oescription

Starting Failures 603.01 (08H)

Faults in Fuel Gil System 603.02 (08H)
Disturbances during Running 603.03 (08H)
Ignition in Crankcase ~ 603.04 (08H)
Trouble Shooting Guide for Air Starter 603.06 (08H)
Trouble Shooting for Cooling Water System 603.09 (08H)
Trouble Shooting for Lubricating Gil Cooler 603.10 (01 H)

92.45 - ESOU 1101 F"BY

~SETS
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Description 603.02
Page 1 (3) Faults in Fuel Oil System Edition 08H

General

Trouble Possible cause Trouble shooting

Engine turns on starting air, but
ignition fails. Fuel pumps are not
actuated
Sluggish movement 01 manoeuv-ring Lubricate and mobilize rod con-
gear nections in manoeuvring gear
Governor setting incorrect Adjust governor, see special in-
struction manual

Overspeed stop tripped Cancel overspeed stop

Piston in stop cylinder is actuated Check lhat piston is not sticking.

Check that pressure in cylinder is
relieved, see also peint 14

.. Piston in stop cylinder is actuated Check pressures and tempera-

owing to uncancelled shut-down tures. Check lor taults in shut-
function (1) down devices

Failures in governor Check that governor is working

properly. For further fault location,
see special instr. manual

Incorrect adjustment of manoeuv-ring Check rod connec. Check that luel

gear pump index is corresponding to
"Adjustments after trials" in testbed
chart

Incorrect adjustment 01 limiter Adjust setting 01 limiter cylinder

cylinder

Engine turns on starting air, but
no luel is injected owing to lailures
in fuel system
Fuel oil service tank empty
Air in fuel pumps and luel injection
valves (2)
Pump oil into lhe tank
Vent the fuel pumps unitl fuel wilh-
out air bubbles appears. II ignition
fails in just one cyl., vent the re-
spective fuel injection valve. If igni-
tion still lails, install a spare valve
before attempting to start the engi-
ne again.

Worn-out luel pump Change luel pumps

Delective fuel injection valves or Change defective fuel valves

valve nozzles (4)

Too low pressure belore fuel injection Increase lhe fuel oil feed pump
pumps (3) pressure

Engine turns on starting air, fuel is Water in lhe fuel Drain off water and repeat venting
injected, but ignitian fails of fuel pumps

Fuel valves or nazzles delective (4) See pein 24

Cont.

92.05 - ESOU IIOI..EBY

CENERATlNG SETS
 MAN
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603.02 Description
Edition08H
Faults in Fuel Oil System Page 2 (3)

General

Trouble Possible cause Trouble shooting

Compression during start toa low (5) Check intake and exhaust valve
for tight closing. Check cyl. wear
and piston rings

Incorrect timing of camshaft (6) Check luel pump timing advance,

and luel valve opening pressure
as well as camshat adjustment

First ignitions are too violent Oil has collected on piston crown (7) Slow turning with open indicator
(safety valves are opening). valves, to locate defective luel val-
Engine runs erratically ve, remove oil

Sluggish movement 01 manoeuvring Lubricate and mobilize rod

gear connec-tions and bearings in
manoeuvring gear

Fuel pump index to high Check rod connection is manoeuv-

ring gear. Check that governor is
working properly. Umiter cylinder
to be set lower

Remarks

1) If the shut-down function is due to overspeed, 4) If the fuel is forced into the cylinder through a
the shut-down impulse is cancelled by setting the defective fuel valve or through worn-out atomizer
overspeed governo r and thus venting the stop cylin- holes, no or toa sluggish atomization may prevent
• der. ignition, possibly tollowed by toa violent ignition.

2) Whether air is present in the fuel oil system is
seen be repeating the venting of fuel pumps. The
cause may be that a fuel valve is kept in open
position (spindle sticking or spring broken). Heating
of fuel to a toa high temperature may have a similar
effect owing to formation of gas in the fuel, If a
sticking valve is found, it should be changed and
overhauled. It should be cheked that no oil has
collected on the piston crown. Air in the fuel oll
system may also be the result of the fuel oil feed
pump sucking-in air through a defective stuffing box
or a leaky seat.
3) If the fuel oil pressure drops, the filter may be
clogged up, or the by-pass at the feed pump may
have opened.
5) To obtain ignition temperature in the cylinders,
the compression pressure during starting should be
normal, see the testbed chart. This can be checked
by measuring the compression pressure during
starting. Cylinders having toa low compres-sion
should be inspected.
6) Major alterations of the combustion charac-
teristics of the fuel may demand adjustment of the
timing of the fuel pumps. One or more cam-shaft
sections may be incorrectly fitted (after dismantling).
Too high opening pressure ofthe fuel valves will also
delay the injection.

HOLEBY
CENERA11NG SETS
92.05 - ESOU
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603.02
Description
Page 3 (3) Faults in Fuel ou System Edition 08H

General

7) Oil on the piston crown will in most cases have
leaked down from a defective fuel valve. As these oil
accumulations are dangerous, the lea-kage should
be found and remedied before the engine is started
again.
Turbocharger Failure
If heavy vibrations, bearing failure or other trouble
arise in a turbocharger, lhe engine load must be
reduced unlil the vibralions cease. When possible,
I~ the engine is stopped in order to locate and remedy
the fault (see turbocharger instr. manual).
If a repair cannot be made on the spot, it is decided
if running may continue, with orwithout lhe defeclive
charger blanked off.
When continuing lhe running with the turbocharger
out of operation, the engine output must be reduced.
The exhaust temperature must not exceed the nor-
mal valve, for full load running with a intact turbo-
charger. For further details see the separate turbo-
charger instr. manual.

"'0-

92.05 o ESOU HOi.!EBY

GENERATlNG SETS

Description
Page 1 (1)
Trouble
Engine turns as soon as shut-otf
valve is opened, without start but-
ton being activated
Engine does not turn when start
button is activated
Engine turns too slowly ar
irregularly when start but-ton is
depressed
90.46 - ESOU
Starting Failures
Possible cause
Faults in electrical system
Air pressure in starting air receiver
too low
Main valve(s) closed
Pinion does not engage the fly
wheel
Air motor runs, pinion engages but
does not rotate
Faults in electrical system
Worn air motor parts
Start valve is sticking in close
posifion
~ ElB:W
603.01
Edition 08H
General
Trouble shooting
Check electrical parts
Start compressors, re-charge air
receiver
Open valve at receiver and stop
valve interposed in line between
receiver and engine
Check the air starter for broken
clutch jaws ar other broken parts
Check the air motor for broken
shafting, bearing ar clutch jaws
Check electrical parts
Remove and disassemble the air
motor. Examine ali parts and re-
place any that are worn or damag-
ed. Use the gúidelines for determi-
ning unserviceable parts
Check start valve
HOLmy
GENERATlNG
SETS
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Description
Trouble Shooting for Cooling Water System
603.09
Page 1 (1)
Edition OBH

General

Description The pump bearings are lubricated automatically with

The built-on tresh water pump in the high tempera-
ture (HT) circuit is ot the centrifugal type and is
mounted on the tront cover ot the engine and is
driven through a gearing.
oil trem the lubricating oil system ot the engine.
11the pump leaks and the shaft sealing rings are
worn, it is recommended to replace the shaft seal,
see work card 616-02.00.

Trouble Possible cause Trouble shooting

The pump does not work after Pump draws in air at suction side Check packings and pipes for
start tighlness

The system is not filled-up Check the levei in lhe expansion

tank

Air cannot escape on delivery side Vent the system

Leaking shaft se ai Check the shaft seal

Pump capacity drops after normal Air leakages of shaft seal Overhaul lhe shaft seal
operation
Fouled impeller Clean lhe impeller

Pump does not give maximum Suction valve not fully open Open the suction valve
delivery :~.,~,.i'·l,
'í~f~f'~;'
..\1 '\.
Defective seals Replace lhe seals
,
Worn impeller and worn wear rings Overhaul the pump

Note! Running troubles with the pump, apart trem

mechanical faults, are most often due to leaks in the
suction line. It is essential, therefore, that ali pack-
ings and gaskets are in order and that they are
renewed when necessary. Even a thiny hole in the
suction line will reduce the pump capacity.

91.14- ESOU

,I
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Description 603.06
Page 1 (1) Trouble Shooting Guide for Air Starter Edition08H

General

Trouble Possible cause Trouble shooting

Loss 01 power Worn motor parts Remove the motor Irom lhe motor
housing (1) and disassemble lhe
motor. Examine ali parts and repla-
ce any that are worn or damaged.
Use the lollowing guidelines lor de-
termining unserviceable parts:

1. Vanes (15) - Install a set of new

vanes il any vane is cracked, spal-
led or worn to the extent that its width
is 24 mm. at either end.
2. Rotar bearings (10 ar 18) -
Replace il any roughness ar loose-
ness is apparent.
3. Rotar (13) - Replace il the body
has deep scoring that cannot be
removed by polishing with emery
cíoth.
4. Cylinder (5) - Replace if there
are any cracks ar deep scoring.
5. End plates (9 or 16) - Clean up
scoring by rubbing it wilh emery
cloth placed on a flat surtace.

Inadequate lubrication Check the lubricator, inlet hose, fit-

ting and oil supply hose to make
sure they are vacuum tight and free
of leaks. Tighten ali joints and re-
place the lubricator if necessary.

Air ar gas leakage Worn seals Check the motor seals (8 ar 31).
Plug the exhaust. Apply 12 bar air to
lhe inlet and immerse the unit for 30
seconds in nonflammable solven!. If
bubbles appear, replace lhe seals.

Pinion does not engage lhe fly- Broken clutch jaws or olher broken Refer to disassembly of lhe drive
wheel parts housing. Working card 613-01.30.

Motor runs, pinion engages but Broken shafting, gearing or clutch Reter to disassembly of lhe drive
does not rotate jaws housing. Working card 613-01.30.

Excessive butt engagements
Dry drive pinion spline
Remove the drive pinion (23) and
lubricate the drive pinion and the
drive shaft helical spline with
grease. Reler to disassembly 01 the
drive housing. Working card 613-
01.30.

91.13 - ESOU
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Description 603.10
Paqe 1 (2) Trouble Shooting for Lubricating Oil Cooler Edition 01H

General

Trouble Shooting_ In case of fatigue fracture, this will normally

In case of damage to plates or gaskets, it will often
be necessary to replace them.
First examine very carefully the external conditions
around the plate heat exchanger in order to localize
the cause of the damage!
necessitate a replacement of ali plates and gaskets
- as there may be a risk of fatigue fracture in ali the
material.
In case of corrosion, ali plates must be examined
carefully!
For work to be carried out see working card 615-
05.00.

Visible Leakage

Trouble Possible cause Trouble shooting

Leakage. Too high pressure. Reduce the pressureto thecorrectwork-

ing pressure, see page,600.30 "Operat-
ing Data & Set Points,i.
,
.'

Leakage. Insulficient tightening Tighten up lhe plate heat exchanger -

(Phase 1) however, notunder the minimum dimen-
sion and never, when lhe plate haat
exchanger is under pressure or over
40"C.

II the plate heat exchanger is stillleaky,

procede with phase 2.

Leakage. Fouled or delormed plates. Separate the plate heat exchanger and
(Phase 2) Inelastic or detorrned gaskets. check il lhe plates are delormed or louled.
Check that the gaskets are elastic and
non-delormed, and that the faces 01 the
joints are clean.
Replace deformed plates and gaskets, if
any.
Belore assembling, clean very carefully
ali plates and gaskets.
, Assemble lhe plate heal exchanger and
start it up again.
Note! Even tiny impurities such as sand
grains may cause leakage.

Separate the plate heat exchanger.

Leakage. Gaskets. Clean the plates very carefully.
(Even after tightening of the plate heat Replace the gaskets.
exchanger to minimum dimension) Assemble the plate heat exchanger and
start it up again.

Leakage. Separate the plate heat exchanger.

(Through the drain holes 01 the gas- Defective gasket or badly corroded Replace defective plates and gaskets, if
kets) plate. any
Assemble the plate heat exchanger and
start it up again.

---
92.08 - ESOU
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603-10 Description
Trouble Shooting for Lubricating Oil Cooler Page 2 (2)
Edition 01H
I

General

Non-Visible Leakage

Trouble Possible cause Trouble shooting

Reduced heat transmission and/or in-
creasing pressure drop.
Fouled plates or choked plate
channels.
Separate the plate heat exchanger and
check if the plates are fouled.
Clean the plates very carefully.
Assemble the plate heat exchanger and
start it up again.

Leakage. Holes in plates. A suspected leakage can be localized in

(The fluids get mixed) Corrosion ar fatigue fracture. the following way:
(Phase 1) Remove one of the lower pipe connec-
tions.
Then put the opposite side under pres-
sure.
If the medium continues to run out of the
lower pipe connections- after the pres-
sure has stabilized - one ar several
plates are leaking.
Close down the plate heat exchanger.
Separate the plate heat exchanger and
.'
check the plates very carefully.
Check suspected plates with a dye pen-
etrant.
Check defective plates and gaskels.
Sefore assembling, ciean ali plates and
gaskets.
Assemble the plate heat exchanger and
check to find more defective plates, if
any, by putting one side under pressure.
Start up again.

Leakage. Holes in plates. Close down the plate heat exchanger.

(The fluids get mixed) Corrosion or fatigue fracture. Separate lhe plate heat exchanger.
(Phase 2) Put ali plates to dry. Suspend the plates
in the plate heat exchanger again and
tighten it.
Circulate medium at full capacity on one
plate side (every second plate channel).
Keep the other plate channels unpres-
surised and free from liquidl
Stop the circulation after a few minutes
of operation and open the plate heat
exchanger again. Take care to avoid
water spraying onto the dry plate síde:
Sy a careful study of the plates it will be
possible to find moist areas, if any, on
the otherwise dry plate sides.
Check these areas with a dye penetrant'
Replace defective plates and gaskets.
t
I
Sefore assembling, clean ali plates and
I
\
.: gaskets.
Assemble the plate heat exchanger and
check to find more defective plates, if
any, by putting one si de under pressure.
Start up again.
If the unit is stillleaking, check ali plates
with a dye penetram!

92.08 - ESOU

Oescription
Ignition in Crankcase
Page 1 (1)
Cause
During running, the atmosphere in the crankcase
contains the same gases (N2-02-C02) in the same
proportions as in the ambient air, but an intense
spray of coarse oil drops is flung around everywhere.
If undue friction and thus heating arises between
sliding surfaces, or heat is transmitted otherwise to
the crankcase, the heated surface will cause eva-
poration of the lubricating oil splashed on to it. When
the oil vapours condense they form a multitude of
minute drops suspended in the atmosphere, i.e. a
milky white oil mist is formed, able to nourish and
spread a flame if ignited. Such ignition may be
caused by the same "hot spot" which produced the
oil mist. If a large quantity of oil mist has developed
before ignition, the burning may cause considerable
pressure rise in the crankcase, forsing the relief
valvestoopen.ln a fewcases, whenpresumablythe
whole crankcase has been filled with oil mist, the
consequential explosion has thrown off crankcase
doors and caused fire in the engine room.
Every precaution should therefore be taken to (A)
avoid "hot spots" and (8) discover oil mist in time.
A. "Hot spots" in crankcase.
Overhauling 01 bearings is a result of too bad or
failing lubrication possibly caused by pullution of the
"'~'. lubricating oi/.
It is therefore important that the lubricating oil filtra-
tion equipment is in perfect condition. Filter cartrid-
ges must not be used again, if they have been
removed from the filter. Check of the oil condition by
analysis is recommended.
B Oil mist in crankcase.
Presence of oil mist may by noted at lhe vent pipe,
which is usually fitted to the top of the engine frame.
Measures (in case of white oil mist).
Warning: Keep away from doors and relief valves
on crankcase. Do not stay unnecessarily in door-
ways near doors of the engine roorn casing.
90.46 - ESOU
r::~
EI&lM
603.04
Edition08H
General
1. Stop the engine
2. Leave the engine room. Shut doors and keep
away from them. Make ready fire-fighting equip-
ment.
Warning: Do not open crankcase until 20 minutes
after stoppong of the engine. When opening up,
keep clear of possible flames. Do not use naked light
and do not smoke.
3. T ake oss ali doors on one side of the crank-
case. Cut off starting air. Engage turning gear, if
fitted.
4. Locate the hot spot. Powerfullamps should be
employed at once (in explosion-proof fittings). Feel
over ali sliding surfaces (bearings, liners, pistons,
roller guides, etc.).
Look for squeezed-out bearing metal and discolo-
ration by heat (blistered paint, burnt oil, heated
steel).
5. Prevent further heating, preferably by making
a permanent repair. Special attention should be
given to ensure lubricating oil supply and satisfac-
tory condition of the frictional surfaces involved. It is
equally important to replace filter elements in time.
7. Start electrically driven lubricating oil pump
and check oil flow from ali bearings and splash pipes
in crankcase while turning the engine through at
least two revolutions. Section 602, Check 1.
8. Stop and feel over. Look out for oil mist.
Especially the frictional surfaces that caused the
heating should be felt over (5-15-30 minutes after
starting, and again when fullload is obtained). Sec-
tion 602, Check 27.
9. In case it has not been possible to locate the
hot spot, point 8 should be intensified and repeated
until the cause of the oil mist has been found and
remedied. In very rare cases oil mist could be due to
"atomization" of lubricating oil by the action of an air
jet (for instance blow-by, or blow-bythrough cracked
piston).
I
HOLEBT
GENERATlNG SETS
 Description
Page 1 (3) Disturbances during Running
r=~ EI&lM

603.03
Edition 08H

General

Trouble Possible cause Trouble shooting

Exhaust temperature(s) (Ali cyls.) Increased charging air ' See section 601 ; Operational Ob-
increase(s) temperature due to ineffective air servations, item e
coolers

(Ali cyls.) Fouling or air and gas Reduce load and water-wash tur-
passages bine. Clean air filters and coolers

(Ali cyls.) Insufficient cleaning of See section 601; Operational Ob-

fuel oil or changed combustion servations, item c
characteristics

(Ali cyls.) Wrong position of cam- Check Pmax" Check camshaft ad-
shaft (Maladjustment) justment

(single cyls.) Fuel valve or valve See section 601; Operational Ob-
nozzle defective servations

(Single cyls.) Leaky exhaust Check lhe vatve clearance. Repla-

valves (1) ce cyl, head with defective valve

(Single cyls.) Blow-by-Ieaky com- See section 601 ; Operational Ob-

bustion chamber (2) servations

(Single cyls.) Damaged fuel pump Check timing advance of fuel

cam pump

Exhaust temperature(s) (Ali cyls.) Decreased charging air Check lhat lhermostatic valve (by-
decrease(s) temperature pass valve) in cold water system is
working properly and correclly set

(Single cyls.) Air in fuel pump(s) Venting of fuel pump(s) unlil fuel
and fuel injection valve(s) without air bubbles appears.
Check feed pump pressure

(Single cyls.) Spindle in fuel valve Change and overhaul defective

sticking (3) fuel valve

(Single cyls.) Fuel pump plunger Change fuel pump plungerlbarrel

sticking or leaking assembly

Engine RPM decreases Pressure before fuel pumps 100 Raise fuel oil feed pump pressure
low to normal. Check filter

Fuel vatve or fuel pump defective Change defective valve or pump

Water in lhe fuel Drain off water and vent lhe fuel
purnps

Governor defective (4) Replace defective governar

Increased internal friction in engine See "Ignition in Crankcase"

(5) Cont.

92.05 - ESOU ----IFBv

H81..__
GENERAl1NG SETS
r /-....
I
603.03
Edition 08H
Disturbances during Running Description
Page2 (3) 'I
I
General

Trouble Possible cause Trouble shooting

Engine stops Shut-down Checkoressure and temperatures.

If OK. check for faults in shut-down
devices. See also Starting Failures

Smoky exhaust Turbine RPM lagging behind en- Reasonably smoke is normal when
gine RPM RPM increases; no measures cal-
100 for. If smoky exhaust during
normal running, dean turbine(s)
and check valves

Air supply too low Fouling 01 air and gas passages,

see section 601; Operational Ob-
servations

Fuel valves or nozzles defective See section 601; Operation ob-

servations

"Trumpets" at nozzle holes. Failure Overhaul fuel valves. Re-establish

01 cooling (especially during hea- nozzle-cooling
vy-oil operation) (6)

Exhaust valve knocking Adjsuting screw for valve setting Inspect and replace defective parts
IOO5e. Push rod thrust disc da- as necessary
maged

Rising cooling water temperature Pump stopped, Increased friction Stop the enqine, Check lhe cooling
(7) water. Find cause of increased
friction and rernedy fault

Lubricating oil pressure lails Lubricating oil pump defective. (8) Stop lhe engine. For further
Filters/cooler fouled details, see "Ignition in crankcase"

Remarks

1) Thís manífests itself by ríse of the exhaust
temperature and fallíng of the compression and
maximum combustion pressure of the respective
cylínder.
To límit the damage to the valves, these should be
changed ímmediately, ít possible, orthe tuel pump ot
the cylínder concerned should be put out 01 opera-
tion by movíng the índex to stop and locking it in thís
posítíon.
2) Blow-by means a serious danger of piston
seizure, and the engine must if possible be stopped
and the piston in question pulled. If thís is not
possíble, the tuel pump index must, as descríbed
above, be moved to stop. Leaky piston rings will
normally result in a heavy excess pressure ín the
crankcase.

HOi..EiiY
CENERATlNC SI:1"S
92.05- ESOU

Description
Disturbances during Running
Page 3 (3)
3) Ifthis happens the fuel pump barrel and plunger
must be changed, and if, to obtain full load of the
respective cylinder, it is necessary to increase the
fuel pump index by more than 10 index degrees, the
fuel pump is in most cases worn out. Usually this is
confirmed by inspection of the fuel pump plunger on
which the helical cut-off edge will show a pitted and
corroded area where material is plucked out. In that
case the pumpcan be provided with a new barrel and
plunger.
4) The governo r will not reduce the fuel pu mp
delivery to zero in case of, for instance, failure of the
governo r oil pump, but the engine speed will start
fluctuating.
When the governo r is defective the engine is pro-
tected against racing by the overspeed trip, i.e. the
engine is stopped automatically in case of excessive
speed. It is essential,therefore, that the overspeed
trip is kept in perfect order. Regarding governor
failure, see special instruction book.
5) Usually a bearing failure will not slow down the
engine appreciably, but the seizure of a piston in the
cylinder liner might do so. If a PG-govemor is
employed, the index will increase and exhaust
temperatures rise. If such cases occur, repair is
necessary before starting the engine again. Feel
over and look out for oil mist.
92.05 - ESOU
\'
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603.03
Edition08H
General
6) If the cooling of the atomizers fails (if arranged
for oil cooling) while running, carbon deposits will
build up round the nozzle holes, sometimes in the \
shape of small cones or trumpets which causes the
engine to smoke, or ot will cause sticking ofthe valve
spindle. Forthis reason the nozzle cooling should be
well maintained.
1
7) If the cooling water temperature for the entire
engine has risen to 90-1 00° C, it should be checked
- by opening the test cocks, if fitted on the discharge
from cylinders - whether steam has developed. If this
is the case, there is no wateron thecooling surfaces,
which may therefore be heated unduly. To avoid
heat stresses arising in cylinder liners and cylinder
heads, if the water returns too early, the engine
shou Id be stopped and left to cool, while the discharge
valve is closed. After 15 minutes it is opened a little
to allowthe water to rise slowly in the cooling jackets.
Check filling attest cocks. Make crankcase inspection
to ascertain that internal water leakage has not
arisen. Remember slow turning withopen indicator
valves at subsequent starting-up.
8) If the lubricating oil pressure drops below the
minimum mentioned in Data; Find the cause of the
pressure drop and remedy the defect before re-
starting the engine. Feel over 5-15-30 minutes after
starting, and again when full load is obtained. See
section 602.
H81.__
----IFBy
GENERATING SETS